Spring unit and method of constructing the same



Jan. 1943. G. c. BURL) mw I SPRING UNIT AND METHOD OF CONSTRUCTING THE SAME Filed Oct. 18, 1938 INVENTOR GUAMH/V a Ell/Pp I B Patented Jan. 26, 1943 SPRING UNIT AND METHOD OF CON- STRUCTING THE SAME Gorman C. Burd, Adrian, Mich., assignor to The Owen Silent Spring Company, Inc., a corporation of Connecticut Application October 18, 1938, Serial No. 235,565

9 Claims.

This invention relates to spring assemblies or units comprising a number of upright helical springs arranged next to each other, and to the method of connecting the springs together and to a frame or frames or the like if desired.

Among the main objects of my invention is the construction of a spring assembly or unit comprising upright helical interconnected springs formed from a continuous wire with the intermediate convolutions of adjacent springs interthreaded and the end convolutions of a running series of springs having their end convolutions integrally connected together by sections of the continuous wire forming the springs which in the case of the springs adjacent the frame pass 4 for constructing a spring assembly or unit in its entirety except for the outer series of springs in the absence of a frame or frames and then in placing the frame or frames in position and connecting the outer series of springs thereto as the construction of the spring assembly is completed.

Other objects will appear from the following description taken in connection with the drawing in which,

Fig. 1 shows a top plan view of my improved spring unit;

Fig. 2 is a broken end view of the spring unit as viewed from the line 22 Fig. 1;

Fig. 3 shows a reel which may be employed in constructing the spring unit;

Fig. 4 is an end elevation of the third, fourth and fifth springs formed in constructing the spring unit;

Fig. 5 is an elevational view of the connection between the last spring of a series of springs made from one coiled wire and the first spring of a second series of springs made from a second coiled'wire supported on successively employed reels; and

Fig. 6 is a top plan view of the first four springs formed in the construction of the spring unit.

For the purpose of describing and claiming my invention, I will refer to the spring assembly disclosed as a spring unit which is intended to be descriptive of assemblies in which the frame is a fixed part of a support as well as constructions in which the frame is mounted on a support and also those in which the assembly is used as an insert for mattresses, cushions or the like.

The spring unit disclosed in Fig. 1 comprises a large number of springs arranged in nine rows of springs each row consisting of ten springs. This number has been selected only for illustration as the spring unit may comprise a larger or smaller number of springs and the spring unit may be made square or of elongated rectangular form or may be given other shapes if desired and the springs may be made of varying lengths. I have indicated the springs in the several figures by reference characters which indicate the order in which they are formed, and I have shown the outer row of springs connected to rectangular frame members uf and bf.

In Fig. 3 I have disclosed a reel 1* such as is disclosed in the patent to Ehlenbeck 1,761,711 of June 3, 1930, which supports a long length of coiled wire. Before spring I is formed I press a plurality of convolutions such as Ia off the reel 1' to provide a connecting spring of less length than the length of the springs of the spring unit, this spring merely constituting an anchoring means between spring I and springs 3, 4 and 5 as shown in Fig, 4.

After the convolutions la have been pressed off, the reel is swung about an axis tangential to the convolutions Ia through an angle of Fig. 3, into the position of spring I, Figs. 1, 4 and 6, ready to form spring I which is connected to the uppermost convolution Ia by the connecting section uc. One convolution is now pressed off to form the uppermost convolution of the spring I after which the reel 1' is passed clockwise through the next to the uppermost convolution la and then another convolution is pressed oif the reel to form the second convolution of the spring I after which the reel is passed clockwise through the next convolution Ia. This operation is repeated until the desired number of convolutions have been pressed off and the sprin I has been completed.

The reel r is then swung 180 about an axis tangential to the convolutions of spring I into the position of spring 2. The lowermost convolution of spring 2 is now pressed off the reel 1' which convolution is connected with the lowermost convolution of spring I by a lower connecting element not disclosed, such as be which connects the springs 3 and 4 in Fig. 4. The reel is lower connector bc.

convolution of spring 3, the uppermost convolu- V tions of springs 3 and. 2 being connected together by an upper connecting element uc. The reel is then passed through the next to the uppermostconvolution la Fig. 4 and the next to the uppermost convolution of spring 2 and then a second convolution is pressed off and this operation is continued until the spring 3 has been completed after which the reel is swung 180 into the position of spring 4 and a turn is pressed off to form the lowermost convolution of spring 4 connected to the lowermost convolution of spring 3 by the The reel is then passed through the convolutions of springs I and 3 and another turn is pressed off and this operation is continued until spring 4 has been formed after which the reel is swung 180 into the position of spring 5, which is formed and enthreaded with the spring 4 as shown in Fig. 4, after which the reel is again swung 180 into the position of spring 6. The spring 6 is now formed and interengaged as it is being formed with springs l and 5' after which the reel is swung into the position of spring I and spring I is formed and so forth. The order in which the springs are preferably formed is indicated by the reference characters within the outlines of the springs and by following the reference characters it will be noted that they are arranged in the form of a rectangular spiral. This operation of forming and interthreading and interlocking the springs is continued until all the wire on reel 1' has been used informing springs.

' ldh. It is assumed that the reel 1 holds enough coiled wire to form nineteen springs. After the spring 19, Fig. 5, has been formed the reel will be swung into the position of spring 2.! and the spring section lSa Fig. 5 will be formed. The next series of springs are formed from a wire on another reel r by first forming spring section ZIwFig. 5, the end of which may be connected to 'a convolution of the spring l9 by a hook 2 lah. The convolutions of both of the springs [9a and Zla will be interlocked with the convolutions of springs i3 and 1 as indicated in Fig. 5. After the convolutions 2m have been formed the reel is swung 180 into the position of spring 2| in which position spring 2! is formed and interconnected with spring 28. The springs 22 to 49 are then formed in the order indicated and interconnected with the previously formed springs. If the wire in the second reel terminates with spring 48 another reel will be used to construct this spring in the same manner in which the spring was constructed. From there on the operation will be continued and as indicated the springs will be formed in the order shown. The

last spring formed from the wire on the third reel may be the spring 55. This spring then is formed in the same way in which spring 20 was formed, after which the spring 5'! is formed and then the fourth reel is swung 180 and about the lower front frame member bf and brought inside of the frame into the position of spring 58 Fig. 2. The spring 58 is then formed and interconnected with the springs 3! and 51 after which the reel is swung and then passed around the upper front frame member uf into the position of spring 59 Figs. 1 and. 2. The spring 59 is then formed and interconnected with springs 32 and 58. After the lowermost convolution of spring 59 has been pressed off the reel is moved about the lower front frame member bf into the position of spring Gil and the spring 60 is then formed. Similarly all the remaining springs are formed and connected to adjacent springs and also connected by upper and lower connecting members ac and be to adjacent springs of the, same course and to the upper and lower frame members M and bf.

In the right hand half of Fig. 2 I have shown springs 65 and 55 in which the connector uc between the springs to and 65 passes around the upper front frame member uf and the connector be between springs 65 and. 66 passes around the lower right hand side frame b! as viewed in Figs. 1 and 2.

The remaining springs of the outer course of the springs in the unit are formed in the same manner and connected to the upper and lower frame members. The last spring to be formed, the spring 953, will have its upper convolution and connector no related to the frame as shown in Fig. l and on the end of the connector we will be formed a short spring to parallel and be connected to the spring 5? by a hook as will now be well understood.

From the description it is apparent that the spring unit may be formed and woven by beginning with a central spring, such as i, and forming and interconnecting springs along a spiral course until the unit has been completed. In the method so far described the unit formed is substantially square and would be exactly square if the operation had been discontinued with the completion of spring 85. If. desired the spring unit may be made elongated by locating the third and fourth, etc. springs in line with the first and second springs before starting to weave about the same as center.

As is apparent from the description and the disclosure each spring in the outer course or convolution of the spiral is connected to both the upper and lower frame members uf and bf bythe upper and lower connecting elements uc and be, as for example as shown in Fig. 2 in which the springs 58 and 59 are connected to the upper front frame member uf by the connector uc connecting their uppermost convolutions and the spring 59 is connected to the lower front frame member by by the connector be which connects its lowermost convolution to the lowermost convolution of the spring 69.

By means of this method also as indicated by the heavier lines in Fig. l the uppermost convolutions of the springs are connected together by connectors uc lying in lines paralleling one diagonal line and terminating near the other diagonal line of the frame and the lowermost convolutions of these spnings are connected by connectors lying on similar diagonal lines extending at right angles to the connectors shown in 1. These connectors connect various springs to the frames in symmetrical relation whereby the springs will be supported symmetrically from the frames providing for a better cushioning action.

It is nowapparent that the spring unit may be constructed and assembled with a frame or frames without the necessity of using clips and cross bars interconnecting the springs transversely of the frames, that the operator may travel continuously in the same direction in constructing the spring unit and that all except the last course of springs may be formed and interconnected before the frames are placed in position. Each spring of the outer course is anchored at its upper and lower ends to the upper and lower frames without the use of clips and the entire assembly of springs considered as a unit is anchored to the frames against transverse movements.

While I have described my method and improved spring assembly with reference to the particular spring unit illustrated, it is to be understood that this has been done for purposes of disclosure and is not to be considered limitative and that I reserve the right to all such changes as fall within the principles of the invention disclosed and the scope of the appended claims.

I claim:

1. A spring unit comprising a large number of interconnected upright helical springs, including an encircling series of integrally connected helical springs.

2. A spring unit comprising a large number of interthreaded upright helical springs, including an encircling series of helical springs integrally connected alternately at the top and bottom of the unit by diagonal connections.

3. A spring unit comprising a large number of interconnected upright helical springs, including an encircling series of helical springs integrally connected alternately at the top and bottom of the unit by diagonal connections and horizontal frame members exterior of said series around which said connections pass.

4. A spring unit consisting of a plurality of parallel rows of upright helical springs made from a continuous wire with the convolutions of the adjacent springs of the same and adjacent rows interthreaded and with the portions of the wire connecting the ends of the convolutions of adjacent springs of the same row interthreaded with the connecting portions of adjacent rows diagonally of said rows.

5. A spring unit consisting of a. plurality of parallel rows of upright helical springs made from a continuous wire with the convolutions of the adjacent springs of the same and adjacent rows interthreaded and. with the portions of the wire connecting the ends of the convolutions of adjacent springs of the same row interthreaded with the connecting portions of adjacent rows diagonally of said rows and a horizontal frame enclosing said spring unit and about which said connecting portions of the adjacent rows of springs extend.

6. A rectangular spring unit comprising a plurality of rows of upright helical springs having their end convolutions connected by integral connecting portions with the connecting portions of adjacent rows interthreaded diagonally of the unit along lines paralleling diagonal lines of the unit and terminating in the vicinity of the intersecting diagonal lines.

7. A rectangular spring unit comprising a plurality of rows of upright helical springs having their end convolutions connected by integral connecting portions with the connecting portions of adjacent rows interthreaded diagonally of the unit along lines paralleling diagonal lines of the unit and terminating in the vicinity of the intersecting diagonal lines, and a horizontal rectangular frame about which the connecting portions of adjacent rows pass.

8. The method of forming a rectangular spring imit consisting of upright helical springs from a continuous wire which consists in forming the springs in succession in the course of a fiat spiral and interthreading the convolutions of adjacent springs in the same and adjacent convolutions of the flat spiral until the unit has been completed except for the last convolution of the flat spiral, in associating said unit with rectangular frames, and in resuming the forming of springs to complete said unit and in passing the portions of the wire connecting adjacent springs about said frame during the step of forming the springs in the outer convolution of said fiat spiral.

9. The method of forming a rectangular spring unit consisting of rows of interthreaded upright helical springs and securing the same to a rectangular frame, which consists in forming and interthreading a plurality of helical springs in; the form of a rectangle of less width and length than a rectangular frame by an amount equal to twice the diameter of a spring, in associating the unit so formed with the rectangular frame and in forming a perpiheral row of springs and interthreading the same with the springs of the unit and with the frame as said springs are formed.

GORMAN C. BURD. 

